International Journal of Mechanical and Production

Engineering Research and Development (IJMPERD)

ISSN (P): 2249-6890; ISSN (E): 2249-8001
Vol. 8, Issue 6, Dec 2018, 365-372
© TJPRC Pvt. Ltd.

QUANTITATIVE EVALUATION OF SHRINKAGE POROSITY IN AlSi9

CAST ALLOY AS FUNCTION OF TITANIUM ADDITION AND

CASTING PARAMETERS

B. AIT EL HAJ, A. BOUAYAD & M. ALAMI

Department of Materials and Processes, National Graduate School of Arts and Crafts,
My Ismail University, Meknes, Morocco
ABSTRACT

In the present research, effects of titanium addition as grain refiner combined with casting parameters on the
porosity in the AlSi9 alloy was studied. Porosity was investigated via TATUR test. The casting parameters studied are:
pouring temperature and initial mold temperature. The total porosity was experimentally quantified by densimetry
method. A small decrease in porosity value was observed with increasing the pouring temperature from 700 to 800 °C. It
has been found that the effect of grain refinement by titanium addition on the porosity is more important, when the liquid
metal was poured at 700 °C. Specimen poured in preheated mold at 300 °C present small values of porosity.

Original Article
KEYWORDS: Porosity, Aluminum-Silicon Alloy, TATUR Test, Grain Refinement & Casting Parameters

Received: Aug 27, 2018; Accepted: Sep 17, 2018; Published: Nov 03, 2018; Paper Id.: IJMPERDDEC201841

INTRODUCTION

Porosity is a major defect, which can occur in cast parts after solidification and affects mechanical
properties [1], in particular a reduction of strength, elastic limit, hardness, and resistance to fatigue. It is commonly
accepted that the porosity in aluminum alloys is due to the existence and combination of two phenomena: hydrogen
dissolution and metal shrinkage during solidification[1, 2]. Gas porosity occurs due to the decrease in the solubility
of hydrogen in aluminum during solidification while shrinkage porosity occurs during the solidification, and is the
result of the difference in density between liquid and solid state. Inability of liquid metal to feed the inter dendritic
regions gives rise to shrinkage[3, 4]. It may occur as micro shrinkage dispersed in the interdendritic regions.

The excellent foundry and mechanical properties of A1- Si alloys make them popular candidates for
automotive applications. The use of aluminum and its alloys in industry has increased considerably in recent
decades. Aluminum silicon alloys (Al-Si) offer excellent castability, good corrosion resistance and good physical
and mechanical properties[5-8].

Considering the porosity formation based on the interdendritic feeding, the control of the formation of the
eutectic and α-Al primary phases is of great importance on solidification mode. Casting quality is improved by
reducing the size of α-Al grains and controlling its morphology through the refinement process. In general, there are
three main methods of grain refinement in aluminum alloys: (i) Cooling rate control, (ii) grain refiner addition, (iii)
Agitation of the metal during cooling[9].

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366 B. Ait El Haj, A. Bouayad & M. Alami

In industry, the treatment of liquid metal plays a predominant role in the multiplication of nucleation sites, which
considerably improve the characteristics of Al-Si alloys[10, 11]. The grain refinement mechanism is based on the creation
of heterogeneous germination sites that are dispersed in the liquid metal. The particles added in very small quantities act as
preferential sites of germination for aluminum dendrites, and thus lead to the reduction in the size of the grains. It is
necessary to create a large number of solidification sites which allow the refinement of the structure, and consequently the
improvement of the mechanical characteristics. Titanium is known as a refiner of proeutectic phase of hypoeutectic Al-Si
alloys [12]. The efficient concentration of this element in the alloy and its effect is therefore the object of this study.

The process parameters are crucial to obtain cast metal, without defect in die casting. The casting temperature and
initial mold temperature affect the solidification by changing the cooling rate. Increasing the cooling rate reduces the
solidification time and refines the grain size. The solidification time directly affects the ability of the liquid to feed the
solidifying interdendritic region. Moreover, the grain size has a great influence on the pore size and their location around
the grain.

In die casting, the initial mold temperature plays an important role in determining the microstructure of cast parts.
In general, a high initial mold temperature has an effect on the microstructure, and thus on the porosity formation.

The TATUR test is sensitive to subtle changes in solidification mode and can be used to study the effect of
solidification conditions and grain refiner addition[13]. In this study, this test was used to quantify the combined effect of
pouring temperature, initial mold temperature and small amount of grain refiner (Titanium) addition on the porosity
formation.

MATERIAL SET METHODS

Studied Alloy

In this study, we used the aluminum silicon alloy EN AC-44400 known by its excellent casting properties, good
resistance to hot tearing and corrosion, good machinability and excellent weldability. The nominal chemical composition is
shown in Table 1:

Table 1: Chemical Composition of the Cast Alloy EN AC-44400 (Wt.%)

The alloy ingots were cut and melted in a graphite crucible using an electric resistance furnace. In order to study
the effect of the casting temperature, four casting temperatures were chosen, namely 700, 730, 765, and 800 °C. The effect
of initial mold temperature was studied and selected to be 150 and 300 °C. Titanium is known to be a grain refiner of the
proeutectic phase of hypoeutectic Al-Si alloys. In order to perform grain refinement and to study the effect of the
concentration of this element in the AlSi9 alloy, titanium is supplied in the melt in the form of potassium fluotitanate
(K2TiF6) salt. The percentage of the titanium by weight of the melt of the metal was: 0.013, 0.045 and 0.065%. The
chemical composition of the samples refined with different quantities of titanium is the average of three values obtained by
the optical spectrometer shown in Table 2. The experimental matrix is listed in Table 3.

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Quantitative Evaluation of Shrinkage Porosity in AlSi9
Al Cast Alloy as 367
Function of Titanium Addition and Casting Parameters

Table 2: Chemical Composition of the Used Casting Alloy AlSi9

i9 (Wt. %)
Alloy Si Mg Fe Cu Zn Mn Ti Al
Untreated sample 8.626 0.022 0.398 0.064 0.41 0.173 0.013 bal.
Grain-refined sample 1 8.652 0.015 0.406 0.058 0.414 0.168 0.045 bal.
Grain-refined sample 2 8.716 0.013 0.416 0.056 0.411 0.173 0.065 bal.

Table 3: Experimental Matrix

Titanium Initial Mold Casting
Test
Percentage (Wt. %) Temperature (°C) Temperature (°C)
(°
1 0.013 150 700
2 0.013 150 730
3 0.013 150 765
4 0.013 150 800
5 0.013 300 700
6 0.013 300 730
7 0.013 300 765
8 0.013 300 800
9 0.045 150 700
10 0.045 150 730
11 0.045 150 765
12 0.045 150 800
13 0.045 300 700
14 0.045 300 730
15 0.045 300 765
16 0.045 300 800
17 0.065 150 700
18 0.065 150 730
19 0.065 150 765
20 0.065 150 800
21 0.065 300 700
22 0.065 300 730
23 0.065 300 765
24 0.065 300 800

TATUR Test

The TATUR test is a technique used to evaluate porosity in aluminum alloys. The TATUR test uses
use a permanent
mold of standard geometry containing two parts,
parts of which, the upper part is conical with an orifice. Figure 1 shows the
TATUR specimen.

Figure 1: Permanent Mold Used to Cast

TATUR Specimen (Mm)[14]

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368 B. Ait El Haj, A. Bouayad & M. Alami

The present study is based on the use of the TATUR test. The liquid metal is poured through the orifice into the
preheated mold. The formation of the shrinkage due to the volume contraction of the metal during solidification is favored
by the conical shape of the upper part of the mold. The TATUR test was performed to quantify shrinkage characteristics of
the aluminum alloys.

Porosity Measurement

Porosity is an easy parameter to define, but not easy to quantify. The method used in this study is a non-
destructive technique of porosity measurement. The densimetry is an industrial choice that is known for its rapidity of
implementation. It will allow direct measurement of all the porosities types (shrinkage porosity, gas porosity). Densimetry
is based on Archimedes’ principle. Quantitative measure of porosity in the material determined from specific gravity by
measuring different weights of the sample in and out of water. The percentage of porosity gp of the sample is deduced from
an ideal density ρ0 (without porosity) with the equation[3]:

=( − )⁄ (1)

It is a double weighing of a sample, once in the air (mair) and another time in the water (mwater). From these two
measurements, the density ratio of the sample to that of the waterρech / ρwateris obtained.

⁄ = ⁄( − ) (2)

The direct measurements of porosity on the test specimens are obtained. In order to draw reliable conclusions, we
measure the porosity of ten specimens cast in the same condition.

RESULTS AND DISCUSSIONSFigure 2 shows different forms of internal and external porosities obtained.
The areas in contact with the metallic mold do not show any porosity, at least visually. It is found that the shrinkage
porosity is concentrated in a middle area around the median line of the cast. Micro and macro-shrinkage are both located in
this middle of the specimen. On the other hand, the external shrinkage such macro retassure appears on the free surface and
manifests itself in different forms as shrinkage pipe and slump. However, no surface slumping is encountered in the top of
the specimens.

Figure 2: Forms and Positions of (a) External and (b) Internal Porosities

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Quantitative Evaluation of Shrinkage Porosity in AlSi9 Cast Alloy as 369
Function of Titanium Addition and Casting Parameters

Near mold’s wall, the cooling rate of the metal is high, and therefore the internal regions of the specimen become
difficult to feed by liquid metal. Once the solidified metal in mold’s wall side comes into contact with that solidified one
from the base, the density of the metal decreases. This result was corroborated by numerical study of porosity [15].

Pouring temperature and initial mold temperature are important parameters for casting Al-Si alloys. Figure
3shows the effect of initial mold temperature and the addition of small amount of grain refiner on porosity in the AlSi9
alloy. It can be seen that high mold temperature decreases porosity values.

1 5 0 °C 1,8
1 ,8 150 °C
3 0 0 °C
300 °C
1,6
1 ,6

1,4
1 ,4
Porosity (%)

1,2

Porosity (%)
1 ,2

1,0
1 ,0

0,8
0 ,8

0 ,6 0,6

0 ,4 0,4
0 ,0 0 0 ,0 1 0 ,0 2 0 ,0 3 0 ,0 4 0 ,0 5 0 ,0 6 0 ,0 7 0,01 0,02 0,03 0 ,0 4 0,05 0,06 0,07
T itan iu m (w t.% ) T itanium (w t.% )

(a) (b)
Figure 3: Effect of Initial Mold Temperature and Titanium Addition on the
Porosity in AlSi9 Alloy Cast at: (a) 700°C,(b) 800°C
Without any grain refiner addition, it is found that the porosity reaches 1.63% for the AlSi9 alloy poured at 700°C
in a mold preheated at 300°C. Whereas, when the initial mold temperature is equal to 150°C, we noted that porosity value
is equal to 1.33%. It can be seen obviously that the initial mold temperature influences the solidification time and thus the
porosity formation.

Due to the conical shape of the upper part of the mold, the metal which is located at the orifice solidifies first and
forms a closed mushy zone which blocks all its supply to liquid metal during solidification. Figure 3(a) shows that the
porosity decreases as the titanium addition increases from 0.013 to 0.065wt. %. With Titanium addition of 0.065wt. %, the
percentage of porosity reaches 0.65% when the initial mold temperature is equal to 300 °C, while the porosity percentage
reaches 0.52% when the initial mold temperature is equal to 150 °C. This decrease is most likely due to the multiplication
of germination sites. The grain refiner forms an intermetallic phase that acts as heterogeneous germination sites, which are
dispersed into the liquid metal. Titanium added increases the number of germination sites for dendrites and reduces the size
of grains, and therefore the pores that appear between the dendrite arms due to the inability of feeding

The pouring temperature is an important parameter, which defines the fluidity of the metal as well as its capacity
to fill the interdendritic zones. Figure4 illustrates the combined effect of casting temperature and initial mold temperature
on the porosity formation in thealloy AlSi9. It has been found that the pouring temperature has a low effect on the porosity
formation. The porosity in the AlSi9 alloy cast in a mold preheated to 150 °C decreases from 1.63% to 1.33%, when the
pouring temperature of the metal increases from 700 to 800 °C.

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370 B. Ait El Haj, A. Bouayad & M. Alami

15 0 °C
1 ,6 5 30 0 °C

1 ,6 0

1 ,5 5

1 ,5 0

Porosity (%)
1 ,4 5

1 ,4 0

1 ,3 5

1 ,3 0

1 ,2 5
700 720 740 760 780 800
P o u ri n g te m p e ra tu re ( ° C )

Figure 4: Combined Effect of Casting Temperature and Initial Mold

Temperature on Porosity Formation in AlSi9 Alloys

CONCLUSIONS

In this work, we quantified the effect of Titanium addition as grain refiner on the AlSi9 cast alloy, and combined
effect of process parameters and grain refinement on porosity formation in AlSi9 alloy. The porosity was evaluated using
the TATUR test. Densimetry was used as a quantitative method for measuring the porosity value in TATUR specimens. It
has been found that the effect of grain refinement by titanium addition on the porosity is more important, when the liquid
metal was poured at 700 °C. A small decrease in porosity value was observed with increasing the pouring temperature
from 700 to 800 °C. It has been observed that the preheated mold at 300 °C present small values of porosity.

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